Wrapping machine



Feb. 13, 1968 Filed Jan. 10, 1966 I TO POWER 1 sup/=1. v

P. SHERMAN v WRAPPING MACHINE 7 Sheets-Sheet 3 Feb. 13, 1968 P. SHERMAN WRAPPING MACHINE 7 Sheets-Sheet Filed Jan. 10, 1966 Feb. 13, 1968 P. SHERMAN 3,368,268

WRAPPING MACHINE Filed Jan. 10, 1966 7 Sheets-Sheet l FIG. 4

Feb. 13, 1968 Filed Jan. 10, 1966 FIG. 5

P. SHERMAN WRAPPING MACHINE 7 Sheets-Sheet F:

Feb. 13, 1968 P. SHERMAN WRAPPING MACHINE 7 Sheets-$heet 6 Filed Jan. 10, 1966 Feb. 13, 1968 P. SHERMAN WRAPPING MACHINE 7 Sheets-Sheet Filed Jan. 10, 1966 vw 0% m5 .3 @N\ .3 .3 RS ow R m QQ I 1 I I w9 j (Q n v I m w@ w. oi m: R

United States Patent Ofiice 3,368,268 WRAPPING MACHINE Philip Sherman, Allentown, Pa., assiguor to Bell Telephone Laboratories, Incorporated, New York, N.Y., a corporation of New York Filed Jan. 10, 1966, Ser. No. 519,762 12 Claims. (Cl. 29-203) ABSTRACT OF THE DISCLOSURE A core is freely removed from a supply spool, suitably tensioned and led to a point where aligned metallic tapes are wrapped by rotating the core and both the supply spool and a take-up about the core axis. The composite wire is then tested for magnetic properties which can be regulated by an annealing furnace after which the wire is wound onto said take-up.

This invention relates to a machine and process for manufacturing miniature magnetic wire, and more particularly, to a machine and process for manufacturing twistor wire.

Recent activity in the field of logic circuits has led to the development of a number of magnetic devices having memory characteristics. One of such devices is twistor wire. The latter comprises a very small diameter electrically conducting core member having wound thereon metallic tapes having specific magnetic properties. Simple twistor wire comprises a core member with one magnetic tape wound thereon. So-called piggy-back twistor wire is comprised of a core member and two or more tapes, one tape wound directly on top of the other on the electrically conducting core member. Typical materials for the tape are remendur and permalloy.

Twistor wire is extremely sensitive to mechanical stresses, therefore requiring careful and exact handling during its manufacture. Inasmuch as typical dimensions of the core member and tapes are measured in mils, the problems in manufacturing products of this nature are considerable. The desired magnetic properties of the finished wire can be altered or changed by inducing stresses iii the core member or in the tapes. Thus, during the entire manufacturing process, the core member cannot be twisted longitudinally or subjected to substantial forces or stresses without altering the desired magnetic properties of the wire.

In addition to changing the magnetic properties of the finished product by inducing stresses in the core member,

the same properties may be changed or altered by the manner in which the tapes are wound on the core member. In order to obtain a finished product in which the magnetic properties are uniform throughout the wire, it is necessary that the number of rotations or Wraps of the tape per linear inch of the core be carefully controlled. Each adjacent winding of the tape cannot overlap, nor can each individual tape be twisted during the Wrapping process. In piggy-back wire, it is necessary that one tape be wound directly on top of the other and that the adjacent windings of tapes do not overlap each other.

Stresses or forces may be imposed upon the core member by using too much tension in the tapes during the wrapping process. Such tension may also cause the core member to twist or turn about its longitudinal axis. Any of these conditions result in a change in electrical and magnetic properties away from the desired properties, or at best, result in unknown electrical and magnetic properties.

The prior art includes a number of machines and processes for the Wrapping, twisting, or stranding of conduc- 3,368,268 Patented Feb. 13, 1968 tors and insulators into wire, cable, and other similar products.

The prior artmachines are not easily adapted to the manufacture of twistor wire. The reason the adaptation cannot be made is because the normal machine is contemplated for the manufacture of a product which is not stress or dimensionally sensitive to the extent of twisi'or wire. For example, the Wrapping of copper tape conductors about a fabric core in order to make flexible conductors does not require substantial control of the tensions in the various members or the number of wraps or revolutions of the copper tapes over the fabric core. If one conductor overlaps its neighbor or is slightly spaced therefrom, the acceptability of the final product will not be substantially affected. Averaging the number of Wraps of the copper tapes over a relatively long length of the conductor will suffice. If the tapes are wrapped about the fabric core under sufficient tension to induce longitudinal twisting of the core, the electrical properties of the finished product will still be acceptable. Since typical dimensions of most electrical wire can be measured in terms of substantial fractions of an inch, prior art processes and machines may be used.

Contrary to the above, in the manufacture of twister wire where a typical diameter dimension of the core member is approximately 3 mils and a typical thickness dimension of the tape is 0.3 mil, all aspects of the manufacturing process must be scaled and very carefully and exactly controlled in order to obtain an acceptable yield from the machine of usable wire.

In order to overcome the problems set forth above, the invention includes means for regulating and controlling all of the mechanical tensions and stresses of the various elements that are used to make the finished product. In addition, the axial rotation of the entire core as it is linearly advanced through the machine is controlled.

The machine is basically comprised of five sub-components. They are: (1) a pay-01f mechanism; (2) a transporting mechanism; (3) a wrapping mechanism; (4) a take-up mechanism; and (5) a driving arrangement. The first step in controlling the entire manufacturing process is to control the power or driving arrangement. This control is obtained by driving all of the subcomponents of the device mentioned above from a singular driving arrangement. The driving arrangement comprises a motor and a plurality of toothed belts and pulleys. All the sub-components of the invention are powered from this singular driving arrangement and are coordinated thereto by means of the toothed belts and pulleys.

The pay-off and take-up mechanisms are driven 'by the driving arrangement in the same direction and at the same rotational speed to ensure that no axial twist is imposed upon the core member.

The pay-off mechanism is comprised of a spool of small diameter copper wire; the latter being used for the core member. The entire pay-01f mechanism, including the spool, rotates with the take-up mechanism in order to prevent twisting of the core member. The pay-out mechanism is similar in principle to a spinning fishing reel. The wire is taken over the rim of the spool, through the axis of the spool, and then fed into the machine through a diamond die.

The function of the die is to establish tension between the die and the second mechanism which is the transporting mechanism. As previously mentioned, control of the tension in the copper wire is extremely critical inasmuch as excessive tension will change the magnetic properties of the finished product, While insuificient tension will allow the core member to twist when the tapes are wound on the core. The twisting of the core member also results in an alteration of the properties of the finished product.

The transporting mechanism is essentially a capstan that is geared to the drive mechanism such that for each predetermined number of revolutions of the machine, the core will be transported linearly through the machine a certain predetermined distance. The transportng mechanism thus determines the number of windings of tape about the core member for each linear inch of translation.

Interposed between the pay-off mechanism and the transporting mechanism is the Wrapping mechanism. The wrapping mechanism receives magnetic tape or tapes from a tape manufacturing portion of the machine, and applies them to the rotating core member.

The tape manufacturing portion comprises a spool of wire that has the desired magnetic characteristics. The wire spool is mounted upon a torque motor or other tension controlling device so that proper tensioning of the tape material will be maintained. As the wire is unwound from the spool by means of a capstan, it is passed through a furnace and then through a series of drawing dies to obtain the proper wire diameter. The wire is then passed between the rollers of a rolling mill and formed into a tape of the desired dimensions. After going through the rolling mill, the tape progresses through a tensioning device that corrects and adjusts the tension and then through a furnace where the magnetic properties of the tape are adjusted if necessary. After passing through the furnace, the tape is fed to the wrapping mechanism which applies it to the rotating core member. The tape is applied at approximately a 45 degree angle to the longitudinal axis of the core and is wound a predetermined number of turns per linear inch of core material.

In the event that the machine is used for the manufacture of piggy-back twistor wire, the various components of the tape manufacturing portion of the machine are duplicated. Instead of making one magnetic tape, the tape manufacturing portion of the machine makes two tapes simultaneously. Both tapes are then fed to the wrapping mechanism where they are applied to the core member, one on top of the other.

The take-up mechanism is essentially another spool whose longitudinal axis is mounted parallel to the longitudinal axis of the machine. Its function is to receive the finished twistor wire as it emerges from the transporting mechanism and wind it upon the spool without imparting any stresses or twists to the product. The take-up mechanism is driven by a torque motor which is in turn directly coupled to the central drive mechanism in order to prevent the adding of stresses to the finished product.

The invention is embodied within a machine that produces a high yield of finished twistor wire from relatively rough supply materials. The high yield of the invention is a result of the careful regulation of the rotation of the various components of the device and the regulation and control of the tension of all of the parts of the twistor Wire during the manufacturing process.

The invention will be better understood, its features and advantages more readily apparent from the study of the following detailed description and drawing, in which:

FIG. 1 is a block diagram or schematic of the machine;

FIG. 2 is a plan section view showing the pay-out mechanism, the transporting mechanism, and the wrapping head;

FIG. 3 is a plan section view showing an annealing furnace and testing station;

FIG. 4 is a plan section view showing the take-up mechanism;

FIG. 5 is a plan view showing the formation and processing of the magnetic tape;

FIG. 6 is an elevation view of the apparatus shown in FIG. 5;

FIG. 7 is a perspective view of a portion of the wrapping mechanism; and

FIG. 8 is a partial section view of the capstan.

As shown in FIG. 1, the machine may be broken down into two general portions. The first portion is the twistor manufacturing line 10 and the second portion is the tape manufacturing line 11. The twistor manufacturing line is comprised of a core pay-out mechanism 12 which is followed by tension adjusting means 13. The core pay-out means 12 supplies a core member 14, which in this instance is a copper wire, to the wrapping head 15. At the wrapping head 15, the tape 107 that is produced from the tape manufacturing line 11 is applied to the core member 14. The wrapping head 15 is followed by a capstan 16 that also includes tension adjusting means. The twistor wire 108, after passing through the capstan 16, is then passed through an annealing and testing station 17. It is then stored in a take-up mechanism 18 that also includes tension adjusting means 19.

The tape manufacturing line 11 comprises a wire supply 20 that includes tension adjusting means 21. The wire supply 20 contains a spool or spools of metallic wire 22 that has the proper electrical and magnetic characteristics for the making of the twistor wire 108. Materials like permalloy and remendur have been used in the past. The wire 22 is pulled from the Wire supply 20 over a guide 23 by means of a capstan and tension adjusting means which are part of a drawing mill 25. From the guide 23 the wire 22 progresses through an annealing furnace 24 and then into the wire drawing mill 25 where the wire 22 is drawn to the proper diameter. After passing through the mill 25, the wire 22 is then formed into a tape 107 by a rolling mill 26. The tape 107 emerging from the mill 26 passes through a tension adjusting device and electric eye 27, through a second annealing furnace 28, and then is joined with the core member 14 into twistor wire 108 at the wrapping head 15.

FIG. 1 shows only one tape manufacturing line 11. If piggy-back twistor wire is to be made, the tape manufacturing line 11 is duplicated in order to make two magnetic tapes for application to the core member 14.

FIG. 2, among other things, shows the core pay-out mechanism 12, the wrapping head 15, and the capstan and tension adjusting means 16. The core pay-out mechanism 12 is mounted upon a support or body of the machine (not shown) by means of pillow blocks 29. Each pillow block includes ball bearings 30.

The mechanism 12 comprises a spool 31 that includes the supply of copper wire that forms the core member 14 of the finished twistor wire 108. The spool 31 is mounted upon an insert 32 that interfits with the main axle member 33 of the pay-out mechanism 12. The longitudinal axis of the spool 31 is coincident with the longitudinal axis of the twistor manufacturing line 10.

The axle member 33 has a flange 109 on the end upon which the spool 31 is mounted. The same end also includes a cavity 34 that is shaped to receive the extended portion of the insert 32.

The insert 32 also includes a flange 111 that is similar in shape to the flange 109 of the axle member 33 but is slightly smaller in diameter. Both flanges, 109 and 111, are adapted to bear against the sides of the spool 31 and to position it with respect to the mechanism 12.

A new spool 31 is loaded in the machine by inserting the extended portion 110 of the insert 32 through the hole in the spool 31. The portion 110 is then inserted into the cavity 34 of the axle 33 until the flanges 109 and 111 both bear against the sides of the spool 31. The insert 32 is rigidly fastened to the axle 33 by means of a set screw 35.

The axle 33 includes a hole 36 that extends through the entire longitudinal length of the center of the axle 33. The insert 32 also includes a hole 37 that extends the entire longitudinal length of the insert 32, and is in alignment with the hole 36 in the axle 33,

Mounted upon the end of the insert 32 and adjacent the flange 111 is a doughnut shaped member 38 that is made from a low friction material like Teflon. The member 38 includes an annular hole 39 that is in alignment with the hole 37 in the insert 32 and the hole 36 in the axle 33. A cover 40 is attached to the flange 109 of the axle member 33 and encloses the spool 31, the flange 111 of the insert 32, and the member 38. The cover 40 is for the purpose of restraining the wire 14 so that it does not unwind uncontrollably from the spool 31.

The axle 33 further includes a pulley 41 that is rigidly mounted to the outside surface of the axle 33. A driving belt 42 fits over the pulley 41 and provides the driving force necessary to turn the pay-out mechanism 12 in the bearings 30 of the blocks 29. In order to ensure rotational control of the mechanism 12, the pulley 41 and belt 42 may further include corresponding teeth (not shown) to reduce slippage between the belt 42 and the pulley 41. The entire pay-out mechanism 12, including the spool 31, the die 45, the die holder 44, and the pulley 46, rotates in concert with the axle 33 as it is driven by the pulley 41 and the belt 42.

On the end of the axle 33 nearest the wrapping head 15, the axle 33 includes a second cavity 43, in which a die holder 44 is positioned. The die holder 44 fixes a diamond sizing die 45 in a position coincident to the longitudinal axis of the axle 33 and the hole 36. The die holder 44 further includes a pulley 46 that is pivotally mounted to the die holder 44 by means of the axle 47.

The core member 14 is unwound over the edge of the spool 31 and the flange 111. It is then taken over the surface of the member 38 and threaded through the annular hole 39, into the hole 37 of the insert 32 and the hole 36 of the axle 33. The member 14 continues through the diamond sizing die 45 and around the pulley 46 and extends toward the wrapping head 15. The member 14 is in an unstressed state between the spool 31 and the die 45 because no forces are exerted upon the member 14 before it reaches the die 45.

FIG. 2 also shows the capstan 16 and the wrapping head 15. FIG. 8 shows the capstan and tension adjusting means 16 in detail. The capstan and tension adjusting means 16 is mounted upon pillow blocks 29 that include ball bearings 30 and comprises a main axle 50 that is supported and journaled in the bearings 30. The axle 50 has a shoulder 48 that butts against one of the bearings 30 and assists in positioning the axle 50 with respect to the blocks 29.

The shoulder 48 includes a groove 49 that is shaped to receive a securing ring 54. The ring 54 is comprised of two semicircular pieces that are rigidly fastened to one of the pillow blocks 29 by means of threaded fasteners 112. The ring 54 holds the axle 50 in its correct position with respect to the blocks 29.

The capstan and tension adjusting means 16 also comprises a body 51 that is fastened to the end of the axle 50 by a pin or threaded fastener 125. A capstan pulley 52 is journaled or pivoted to the body 51 by means of a pivot or axle 53. A bevel gear 119 is also rigidly attached to the axle 53. The bevel gear 119 is mated with a second bevel gear 118 that is mounted on the same axle 120 as a spur gear 117.

The axle 50 has a longitudinal bore or hole 113 that extends the entire length of the axle 50. A grounding plate 114 having an extended portion 115 is secured to one of the blocks 29 by pins or threaded fasteners 126. The extended portion 115 fits in the hole 113 of the axle '0 and protrudes out of the other end of the axle 50 adjacent the gear 117. One end of the portion 115 includes teeth and forms a driving gear 116. The gear 116 mates with the gear 117. The gear end of the portion 115 is located in a recess or cavity 127 in the axle 50 and is rotatably supported therein by a bearing 128. The bearing 128 is positioned and held in position by a retaining ring 129.

The hole 113 in the axle 50 is of substantially greater diameter than the outside diameter of the portion 115. Since the axle 50 is journaled in the bearings 30 and the portion 113 is fixed to the block 29, the axle 50 is free to rotate about the stationary portion 115. Rotation of the axle 50 causes the driving gear 116 to turn the gear 117. Turning of the gear 117 results in the rest of the gears 118 and 119 in the train to turn. This causes the axle 53 to turn which causes the pulley 52 to turn. Since the twistor Wire 108 is wound around the capstan pulley 52, the capstan pulley 52 pulls the twistor Wire 108 from the spool 31, through the die 45, and then through the wrapping head 15.

It should be noted that the choice of gears contained Within the body 51 determines the rotational speed of the capstan pulley 52. Thus, the linear velocity with which the core member 14 is pulled through the machine depends upon the ratio of teeth in the various gears. As a result, the number of turns of the core wire 14 per linear inch of translation can be very carefully controlled. A linear translation of one inch for 92 turns of the member 14 has been used.

The torque required on the capstan pulley 52 to pull the member 14 through the wrapping head 15 along with the resistance of the wire 14 to be drawn through the die 45, determines the tension in the core member 14 between the die 45 and the capstan pulley 52. If the tension is too great, the properties of the twistor wire 108 may be altered due to damaging stresses. If the tension in the member 14 is insufficient, the tension in the tapes 107 may cause the member 14 to twist which may result in damaging alterations of the twistor properties.

An inspection of FIGS. 2, 3, and 8 shows that the extended portion includes a longitudinal hole or bore 131 that extends the complete length of the portion 115. The body 51 includes a hole that is in registry with the hole 129. The twistor wire 108 passes around the capstan pulley 52, through the hole 130 of the body 51 and then into the bore 131 of the portion 115.

The axle 58 further includes a driving pulley 55 that is rigidly attached to the axle 50. A driving belt 56 turns the pulley 55 and the axle 50. Like the pulley 41 and belt 42, the pulley 55 and belt 56 may include complementary teeth in order to provide more tractive power and also to ensure rotational control of the axle 50. The belt 56 is driven at the same speed as the belt 42 by the same power unit that drives the belt 42. Thus, the axle 33 and the axle 50 are controlled and rotate together in the same direction and at the same speed.

The wire 108 proceeds out of the bore 131 and through an annealing and testing station 17. The annealing and testing station includes an annular furnace 57 and a testing station 58. The fumace 57 is comprised of a tubular shell 59 and two end pieces 60. Each end piece includes an opening 61 that is coincident to the longitudinal axis of the furnace 57. A tubular heating element 62 is mounted in the end pieces 60 so that it is also in alignment with the longitudinal axis of the furnace 57 and with the opening 61 in the end pieces 68. The rest of the cavity in the furnace 57 is filled with insulating material 63.

The twistor wire 108, as already mentioned, is sensitive to mechanical stresses and forces. It is therefore the purpose of the furnace 57 to heat and anneal the wire 108 as it passes through the furnace. The annealing process compensates and adjusts for deviations from the desired electrical and magnetic properties of the wire 108 caused by stresses and strains that have been imposed upon the product during its manufacture. Though it is desired to keep such stresses and strains to a minimum, if they happen to be imposed upon the Wire 108, the furnace 57 is capable of correcting the faults introduced during the manufacturing process. Furnace 57 makes these corrections in conventional fashion by subjecting the wire to higher or lower temperature levels, depending on the extent of annealing necessary to adjust for the mentioned deviations from the desired electrical and magnetic properties.

After passing through the annealing furnace 57, the wire is passed through a testing station 58. The station 58 includes conventional instruments such as sensing coils, amplifiers, oscilloscopes and other apparatus well known in the testing art, that can measure and analyze the qualities of the finished twistor wire 108 for electrical, magnetic, and memory characteristics. These include switching time, coercive force, etc. If the tests conducted at station 58 so indicate, adjustments in the twistor manufacturing line 10 or the tape manufacturing line 11 are made to correct the manufacturing process so that the desired product qualities are obtained. These adjustments may be made automatically by servo mechanisms or their like means or manually, and will include for example the temperature of furnace 57, the tension of tape 27 and the pressure of rolling mill 26.

After passing through the testing station 58, the twistor wire 108 passes into the take-up mechanism 18. The takeup mechanism 18, similar to the rest of the twistor manufacturing line 10, is mounted upon pillow blocks 29, each of which includes ball bearings 30.

The take-up mechanism 18 comprises a driving axle 64 that includes thereon a driving pulley 65 and a belt 66. As previously described, the pulley 65 and belt 66 may include complementary teeth so as to ensure the rotation of the driving axle 64 in concert with the axles t) and 33 of the rest of the twistor manufacturing line 10. The belt 66 is driven by the same power source that drives the belts 56 and 42. It is required that all the axles 33, 50, and 64 of the twistor manufacturing line turn in the same direction and at the same rotational velocity so that no axial twist is imparted to the core member 14 or the finished twistor wire 168.

The axle 64 includes a longitudinal hole 67 that extends parallel to and coincidental with the longitudinal axis of the axle 64. At one end of the axle 64, a pulley 68 is mounted near the end of the hole 67. The pulley 68 is pivoted on an axle 69 and is adapted to guide the twistor wire 108 as it progresses through the hole 67 and also to position the wire 168 for winding upon the take-up spool 70.

The axle 64 further includes a wrapping carriage 71 that is rigidly mounted to the end of the axle 64 adjacent the pulley 68. The carriage 71 rotates with the axle 64 and includes a counter-weighted section 72 in order to dynamically balance the carriage 71. The carriage 71 has mounted thereon a series of guide pulleys 73 that are adapted to guide and position the twistor wire 108 as it emerges from the end of the axle 64 and over the pulley 68 so that it may be wound upon the take-up spool 70.

The take-up mechanism 18 further includes a support 74 having attached thereto two guide rods 75. A level winding carriage 76 rides upon the guide rods 75. The carriage 76 is driven back and forth along the guide rods 75 by means of a lead screw 77. The purpose for driving the carriage 76 back and forth is to level wind the twistor wire 108 on the spool 70. Thus, as shown in FIG. 4, the twistor wire 108 is wound upon the spool 70 in a level manner by means of the carriage 76 moving back and forth underneath the carriage 71. The carriage 76 further includes two miscroswitches 78 whose purpose is to limit or define the extent of the travel of the carriage 76 upon the rods 75.

The spool 70 is connected to the carriage 76 by means of a torque motor 79. The torque motor 79 establishes the tension in the twistor wire 108 between the take-up mechanism 18 and the capstan and tension adjusting means 16. By means of varying the torque and speed of rotation of the spool 70, the torque motor 79 ensures the proper tensioning of the twistor wire 108 between the spool 70 and the capstan pulley 52. The proper tension in the wire 108 between the pulley 52 and the spool 70 allows the furnace 57 to correctly adjust the properties of the wire 108 and also provides the required tension on the furnace side of the capstan and tension adjusting means 16 for the operation of the latter means.

From a study of the twistor manufacturing line 10 as it has been disclosed above, it can be seen that both ends of the core member 14 rotate in the same direction and at the same speed. Taking into account the change in diameters due to the wrapping of the wire 108 on the spool 70, no twist is imparted to the core member 14 which would change the mechanical or electrical properties of the finished product.

The tape manufacturing line 11 is shown in FIGS. 5 and 6. Although only one line is shown, it is obvious that if piggy-back twistor wire 108 is to be manufactured, the tape manufacturing line 11 shown in FIGS. 5 and 6 may be duplicated in order to form two magnetic tapes 107. FIG. 2 shows two tapes 107 being fed to the guide block 102 as if the machine was set up for producing piggyback twistor wire 108. Like the twistor manufacturing line 10, it is important to maintain and control the tension of the material in the tape manufacturing line 11 throughout the entire manufacturing process.

The tape manufacturing line 11 comprises a support 80 upon which the various mechanisms are mounted. A wire supply 20 is comprised of a spool 81 that has magnetic wire 22 wound thereon. The spool 81 is mounted upon the output shaft 83 of a torque motor 82. The torque motor 82 is a tension adjusting means 21 and adjusts and controls the tension in the wire 22 between the supply spool 81 and subsequent mechanisms in the tape manufacturing line 11.

The wire 22 is pulled from the spool 81 and over a guide 23 by means of a capstan that will be subsequently described. The guide 23 comprises a pulley 86 that is rotatably mounted on the axle 87. After passing through the guide 23, the wire progresses through a furnace 24 in which the electrical and mechanical properties of the wire 22 are adjusted for subsequent manufacturing steps.

The annealing furnace 24 is followed by a wire drawing mill 25 in which the wire 22 is sized to the appropriate dimensions for the manufacture of tape 107.

The drawing mill 25 is comprised of a series of dies 84 that are floatably mounted in a die support 121. The support 121 further includes lubricators 88 which lubricate the wire 22 as it is drawn through the dies 84. On one side of the dies 84 are located a plurality of guide pulleys 89 of varying diameters. The pulleys 89 align and guide the wire 22 as it is pulled back and forth through the dies 84. The pulleys 89 are mounted upon one axle but they are free to rotate independently of each other. The dies 84 are free to move within the support 121 in order to align themselves with the pulleys 89.

On the other side of the dies 84, a substantially conical capstan is located. The capstan 85 is comprised of a solid piece having a plurality of varying diameter portions. In one sequence starting closest to the support 80, each adjacent diameter portion is of a larger diameter than its predecessor so that the 'overall shape of the capstan 85 is essentially conical. The capstan 85 is driven as a unit by the motor 90 of the rolling mill 26.

As shown in FIGS. 5 and 6, the wire 22 is threaded across one pulley 89, through a lubricator 88, through a first sizing die 84, and then around the smallest diameter of the capstan 85 and then back through the drawing mill 25. This process is repeated back and forth until the wire 22 has passed around all the guide pulleys 89, through all of the sizing dies 84 and around all diameters of the capstan 85. As the wire 22 emerges from the drawing mill 25, it is of appropriate size for the tape manufacturing steps.

The reason the capstan 85 is comprised of varying diameter portions is to account for the increase in length in the wire 22 caused by the reduction in diameter of the wire 22 as it is pulled through the die 84. It is essential, as previously mentioned, that the linear speed and tension of all the component parts of the twistor wire 108 be carefully controlled throughout the entire process.

The smallest diameter portion of the capstan 85 pulls the wire 22 through the first sizing die 84. It also is responsible for pulling the wire 22 through the furnace 24, across the guide pulley 86 and from the supply spool 81.

The wire 22 proceeds through a rolling mill 26 that is comprised of a motor 90 and two rollers 91. Each of the rollers 91 are mounted upon an arm 122 and 123 of a yoke 92 and are driven by the motor 90. An adjusting screw 93 is connected to the arms. 122 and 123 of the yoke 92. Turning of the screw 93 moves the arm 122 either closer to or farther away from the arm 123. The pressure between the rollers 91 is thereby varied by moving the rollers 91 either closer to or farther apart from each other. Thus, the dimensions of the tape 107 that emerges from the rollers 91 can be controlled because they are dependent upon the pressure that the rollers 91 exert upon the wire 22.

In addition to the function of flattening the wire 22 into a tape 107, the rollers 91 further establish the tension in the wire 22 between the rolling mill 26 and the drawing mill 25.

The next mechanism in the tape manufacturing line 11 is a tension device 27. The tension device 27 includes a torque motor 94 having mounted thereon a pulley 95. Two pulleys 96 are pivotally mounted to the support 80. The support 80 further includes a slot 97 in which a block 93 is located. The block 98 slides up and down in the slot 97 and has a pulley 99 pivotally mounted to it. A wire 100 is wound upon the pulley 95. One end of the wire 100 is attached to the top of the block 98 and the other end is attached to the pulley 95. By means of the wire 100, the torque motor 94 lifts or lowers the block 98 in the slot 97. The tape 107, as it emerges from the rolling mill 26, is wound under the first pulley 96, over the pulley 99 and then under the second pulley 96 of the tensioning means 27. The tension in the tape 107 is adjusted by means of the torque motor 94. If the block 98 is lifted, the tension in the tape 107 is increased, and if it is lowered, the tension in the tape 107 is decreased.

The tensioning means 26 further includes an electric eye 101 which is operatively connected to the power source (not shown) for the entire machine. If the tape 107 should break, the electric eye 101 is adapted to turn off the power to the machine.

The electric eye 101 also includes two photocells 132 that are adapted to monitor the change in position of the block 98. If the tape manufacturing line 11 produces tape 10'] at a rate in excess of the demand of the twistor manufacturing portion 10, the block 90 will rise in order to maintain the proper degree of tension in the tape 107. As the block 98 rises in the slot 97, the cells 132 of the eye 101 signal a servo mechanism (not shown) that slows down the motors in the tape manufacturing line 11. Tape 107 is then produced at a slower rate.

If the tape 107 is produced at a rate slower than the demand of the twistor manufacturing line 10, the block 98 lowers in the slot 97. The lowering of the block 98 is sensed by the eye 101 with the opposite result described above. The motor speeds in the tape manufacturing line 11 are increased with a resulting increase in production of tape 107.

Thus, the electric eye 101 serves the function of coordinating the two lines 10 and 11 by adjusting the rate at which tape 107 is supplied to the twistor manufacturing line 10. It serves the added function of shutting down the machine if a break occurs.

The final mechanism in the tape manufacturing line 11 is an annealing furnace 28 which is similar to the furnace 57 shown in FIG. 3. The purpose of the furnace 28 is to control and adjust the magnetic properties of the tape 107 before it is wound upon the core member 14 in the twistor manufacturing line 10.

From the furnace 28, the tape 107 progresses to the wrapping head 15 which is shown in FIG. 2. For exemplary purposes, FIG. 2 shows two tapes 107 being wrapped upon the core member 14 in a piggy-back manner. The wrapping head 15 comprises a guide block 102 which aligns the tape-s 107 one on top of the other and positions them for the wrapping die 103.

The guide block 102 shown in FIG. 2 is needed when two tapes 107 are supplied to the wrapping die 103. A wedge-shaped member 124 is adjustably mounted on the block 102. The member 124 fits into a wedge-shaped groove in the block 102 and forms two converging passageways for the tapes 107. The passageways align the tapes 107 and place one tape 107 on top of the other before they enter the hole in the wrapping die 103. The wrapping die 103 is held adjacent the core member 14 by means of a post support 104.

As shown in FIG. 7, the wrapping die 103 comprises a tubular member having located therein an annular hole 105. The hole 105 is oval-shaped so that the two tapes 107 (or one tape if simple twistor wire is being made) are applied to the member 14, one on top of the other, and so that the tapes 107 cannot turn with respect to each other in the hole 105.

FIG. 2 also shows a microswitch 106 that may be used similar to the electric eye 101. If the twistor wire 108 should break, the microswitch 106 stops the machine by shutting off the power.

It is obvious to those skilled in the art that numerous changes and modifications may be made to the illustrative embodiment disclosed above without departing from the spirit and scope of the invention as set forth in the claims appended below.

What is claimed is:

1. A machine for wrapping a thin flattened continuous member on a round elongated continuous core, said machine comprising core supply means and take-up means, means including said supply means and said take-up means for rotating said core about its longitudinal axis without twisting said core, means for transporting said core between said supply means and said take-up means, a first tension means for establishing a controlled degree of tension in said core, and wrapping means for applying said member to said rotating core at a controlled rate and a particular angle, said wrapping means comprising dispensing means for supplying said member in a relatively unfinished state, means for forming said member into a thin flattened tape and a second tension means for establishing a controlled degree of tension in said member between said dispensing means and said wrapping means.

2. Apparatus according to claim 1, further comprising adjusting means interposed between said means for forming said member and said wrapping means, said adjusting means adapted to adjust said member to obtain desired magnetic properties.

3. Apparatus according to claim 2 wherein said machine includes synchronizing means, said synchronizing means adapted to respond to the tension in said member and adjust the supply rate of said member according to the demand of said wrapping means for said member.

4. A machine for wrapping a plurality of thin flattened continuous members on a round elongated continuous core, said machine comprising core supply means and take-up means, means including said supply means and said take-up means for rotating said core about its longitudinal axis without twisting said core, means for transporting said core between said supply means and said take-up means, a first tension means for establishing a controlled degree of tension in said core, and wrapping means for applying said members to said rotating core at a controlled rate and a particular angle, said wrapping means applying said members to said core one member exactly on top of the other, said wrapping means comprising dispensing means for supplying said members in a relatively unfinished state, means for forming said members into thin flattened tapes and, a second tension means for establishing a cont-rolled degree of tension in said members between said transporting means and said wrapping means.

5. Apparatus according to claim 4 further including adjusting means interposed between said means for forming said members and said wrapping means, said adjusting means including an annealing furnace adapted to treat said member to obtain desired magnetic properties.

6. Apparatus according to claim 5 wherein said machine includes synchronizing means, said synchronizing means adapted to respond to the tension in said members and adjust the supply rate of said members according to the demand of said wrapping means for said members.

7. A machine for making magnetic memory wire wherein said wire comprises an electrical conductor with two tapes wound longitudinally thereon, one exactly on top of the other, said machine comprises pay-off and take-up means, means including said pay-off and take-up means for rotating said conductor about its longitudinal axis, the payoff portion of said means including means for dispensing said conductor in an unstressed condition, transporting means interposed between said pay-off portion and the take-up portion of said first mentioned means, said transporting means adapted to transport said conductor through said machine at a controlled linear velocity, wrapping means interposed between said transporting means and said pay-off portion, said wrapping means including spools for tape material, means for forming said tape material into a plurality of tapes, tensioning means located between said pay-01f portion and said transporting means for establishing a controlled degree of tension in said core between said pay-oil portion and said transporting means, tensioning means located between said transporting means and said take-up portion for establishing a controlled degree of tension in said core between said transporting means and said take-up means, and tensioning means located between said wrapping means and said transporting means for establishing a controlled degree of tension in said members between said wrapping means and said transporting means.

8. A machine for wrapping a plurality of continuous members on an elongated continuous core, said machine comprising core supply means and take-up means, means including said supply means and said take-up means for rotating said core about its longitudinal axis without twisting said core, transporting means interposed between said supply means and said take-up means, a first tension means located between said supply means and said transporting means, said first tension means establishing a controlled degree of tension in said core between said tension means and said transporting means, said transporting means moving said core between said first tension means and said transporting means at a controlled linear velocity, a second tension means establishing a controlled degree of tension in said core between said transporting means and said take-up means, and, wrapping means interposed between said first tension means and said transporting means, said wrapping means applying said members at a particular angle, one on top of the other, to said rotating core, said wrapping means including a die having an oval shaped aperture therein, the side walls of said aperture forcing said members to a position one on top of the other and preventing longitudinal twisting of said members.

9. The device described in claim 8 wherein said wrapping means includes a third tension means, said third tension means establishing a controlled degree of tension in said members.

10. The device described in claim 9 wherein said supply means further comprises means for dispensing said core toward said transporting means in an unstressed state.

11. The device described in claim 10 wherein testing and adjusting means are interposed between said transporting means and said take-up means, said testing and adjusting means testing the composite core and members for electrical and magnetic deviations from predetermined standards, and further comprising means for adjusting said first and second tension means of said machine to correct said deviations.

12. The device described in claim 10 wherein testing and adjusting means are interposed between said transporting means and said take-up means, said adjusting means including an annealing furnace, said testing and adjusting means testing the composite core and members for deviations from predetermined electrical and magnetic standards and annealing said composite core and members to correct said deviations.

References Cited UNITED STATES PATENTS 2,000,104 5/1935 Somerville 579 2,255,108 9/1941 Fischer 57--11 2,360,783 10/1944 MacCreadie 57-13 2,444,001 6/1948 Arens 57-43 3,233,397 2/1966 Bonikowski 57-13 BILLY S. TAYLOR, Primary Examiner. 

